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Trane Technologies Thermo King SG 3000e Series Maintenance Manual

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Maintenance Manual
Container Edition
SG 3000e Series
SGSM 3000e, SGCM 3000e, and SGCO 3000e Units
Revision A
6 6 1 1 9 9 7 7 9 9 - - 4 4 - - M M M M - - E E N N
February 2022

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Summary of Contents for Trane Technologies Thermo King SG 3000e Series

  • Page 1 Maintenance Manual Container Edition SG 3000e Series SGSM 3000e, SGCM 3000e, and SGCO 3000e Units Revision A 6 6 1 1 9 9 7 7 9 9 - - 4 4 - - M M M M - - E E N N February 2022...

  • Page 2: P P H H O O T T O O S S , , I I L L L L U U S S T T R R A A T T I I O O N N S S A A N N D D M M E E A A S S U U R R E E M M E E N N T T S

    The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo King units. SM: Side-mount unit frame CM: Center-mount unit frame Model Nomenclature CO: Clip-on unit frame Revision History Revision A (01/2022) New Manual. ©2022 Trane Technologies 61979-4-MM-EN...
  • Page 3 I I n n t t r r o o d d u u c c t t i i o o n n Customer Satisfaction Survey Let your voice be heard! Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a web browser.

  • Page 4: Table Of Contents

    Table of Contents S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s ................................9 9 Danger, Warning, Caution, and Notice .
  • Page 5 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s ....................2 2 6 6 SG+ 1.5 Controller Description .
  • Page 6 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Controls................. . 71 Unit Configuration .
  • Page 7 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Fuel Filter/Water Separator..............102 Fuel Filter/Water Separator Replacement .
  • Page 8 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s SGSM Keener Arm Unit Installation ............131 SGCM Unit Installation .

  • Page 9: Danger, Warning, Caution, And Notice

    Safety Precautions Danger, Warning, Caution, and Notice Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices. Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions.

  • Page 10: Electrical Hazards

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! A A l l l l u u n n i i t t m m o o u u n n t t i i n n g g b b o o l l t t s s m m u u s s t t b b e e i i n n s s t t a a l l l l e e d d , , b b e e t t h h e e c c o o r r r r e e c c t t l l e e n n g g t t h h f f o o r r t t h h e e i i r r a a p p p p l l i i c c a a t t i i o o n n , , a a n n d d t t o o r r q q u u e e d d t t o o s s p p e e c c i i f f i i c c a a t t i i o o n n s s .

  • Page 11: Low Voltage

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G P P e e r r s s o o n n a a l l P P r r o o t t e e c c t t i i v v e e E E q q u u i i p p m m e e n n t t ( ( P P P P E E ) ) R R e e q q u u i i r r e e d d ! ! I I n n t t h h e e e e v v e e n n t t o o f f a a n n e e l l e e c c t t r r i i c c a a l l a a c c c c i i d d e e n n t t , , a a l l l l r r e e q q u u i i r r e e d d P P P P E E s s h h o o u u l l d d b b e e n n e e a a r r t t h h e e w w o o r r k k a a r r e e a a i i n n a a c c c c o o r r d d a a n n c c e e w w i i t t h h O O S S H H A A , , N N F F P P E E 7 7 0 0 E E , , o o r r o o t t h h e e r r l l o o c c a a l l , , s s t t a a t t e e , , o o r r c c o o u u n n t t r r y y - - s s p p e e c c i i f f i i c c r r e e q q u u i i r r e e m m e e n n t t s s f f o o r r a a C C a a t t e e g g o o r r y y 2 2 r r i i s s k k .

  • Page 12: Battery Removal

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G H H a a z z a a r r d d o o f f E E x x p p l l o o s s i i o o n n ! ! A A l l w w a a y y s s c c o o v v e e r r b b a a t t t t e e r r y y t t e e r r m m i i n n a a l l s s t t o o p p r r e e v v e e n n t t t t h h e e m m f f r r o o m m m m a a k k i i n n g g c c o o n n t t a a c c t t w w i i t t h h m m e e t t a a l l c c o o m m p p o o n n e e n n t t s s d d u u r r i i n n g g b b a a t t t t e e r r y y i i n n s s t t a a l l l l a a t t i i o o n n .

  • Page 13: Controller / Microprocessor Service Precautions

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Controller / Microprocessor Service Precautions Take precautions to prevent electrostatic discharge when servicing the controller or microprocessor and its related components.
  • Page 14 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s • I I n n g g e e s s t t i i o o n n : : Do not induce vomiting. Immediately contact local poison control center or physician. B B A A T T T T E E R R Y Y A A C C I I D D •...

  • Page 15: Generator

    Specifications Generator Type 460/230 Vac, 3 Phase, 60/50 Hz Output Power 15 Kw Kilovolt-Amperes 18.75 kVA 1800 RPM Electrical Control System Controls SG+ 1.5 Microprocessor Controller Voltage 12.5 Vdc (nominal) Battery 12 Volts, Group 31, 925 / 950 CCA @ -18 C (0 F) Fuse SI1 (Located on Control 30 Amp - RL4 Relay Fuse board)

  • Page 16: Engine

    S S p p e e c c i i f f i i c c a a t t i i o o n n s s Engine SG 3000e Model TK486VG Tier 2 EPA Fuel Type Diesel fuel must conform to EN590 Oil Capacity 12.3 litre (13 qt) Fill to full mark on dipstick Oil Type...

  • Page 17: Controller Default Settings

    S S p p e e c c i i f f i i c c a a t t i i o o n n s s Controller Default Settings Setting — Menu Location Default Setting Tank Size – Commands/System SGCO Units: 125 gallons (473L) Setup SGCM Units: 50 gallons (189L) , OR 80 gallons (303L)
  • Page 18 Maintenance Inspection Schedule Every Every Pretrip Inspect/Service These Items 1,500 3,000 Hours Hours* Microprocessor: Run Pretrip Test (see “Performing a Pretrip Test”). • Engine: Check fuel supply. • Check engine oil level. • Listen for unusual noises, vibrations, etc. • •...

  • Page 19: General Description

    Unit Description General Description Thermo King generator sets (clip-on and under-mount) are self-contained fully-automatic, diesel powered units. The generator sets supply 230 or 460 Vac electrical power for container refrigeration units. Enclosed within the unit frame are the engine, dual voltage alternator, generator battery compartment, battery charging regulator and control panel. C C A A U U T T I I O O N N R R i i s s k k o o f f I I n n j j u u r r y y ! ! D D O O N N O O T T a a t t t t e e m m p p t t t t o o o o p p e e r r a a t t e e o o r r m m a a i i n n t t a a i i n n t t h h e e g g e e n n e e r r a a t t o o r r u u n n t t i i l l y y o o u u h h a a v v e e c c o o m m p p l l e e t t e e l l y y f f a a m m i i l l i i a a r r i i z z e e d d y y o o u u r r s s e e l l f f w w i i t t h h t t h h e e...

  • Page 20: Emi 3000

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n EMI 3000 These units are equipped with an EMI 3000 Extended Maintenance Interval package. The EMI 3000 package will result in lower total unit life cycle cost, because maintenance intervals have an important impact on unit operating costs.

  • Page 21: Sg Microprocessor Controller

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n SG Microprocessor Controller The SG Microprocessor controller controls and monitors unit operation, records system faults and performs an automatic pre-trip check.

  • Page 22: Sgco 3000E

    Photos, Illustrations and Measurements SGCO 3000e BEE992 Fuel tank Cap Front Access Doors Corner Casting Mount Control Box Location Pin mount 61979-4-MM-EN...

  • Page 23: Sgcm 3000E

    P P h h o o t t o o s s , , I I l l l l u u s s t t r r a a t t i i o o n n s s a a n n d d M M e e a a s s u u r r e e m m e e n n t t s s SGCM 3000e BEE993 Fuel Tank Cap...

  • Page 24: Sgco 3000E Control Box

    P P h h o o t t o o s s , , I I l l l l u u s s t t r r a a t t i i o o n n s s a a n n d d M M e e a a s s u u r r e e m m e e n n t t s s SGCO 3000e Control Box BEE995 Flashload / Download port...
  • Page 25 Genset Model Features SGSM 3000e SGCM 3000e SGCO 3000e Model TK486VG Tier 2 EPA Diesel Engine 460 Vac and 230 Vac 21 KW, 26.25 KVA, 3 Phase, 50/60 Hz, 4 Wire Generator SG+ Control System Battery with Post Battery Charging System, Solid-state —...

  • Page 26: Sg+ 1.5 Controller Description

    SG+ 1.5 Controller and Operating Instructions SG+ 1.5 Controller Description The SG+ 1.5 controller is a two-piece, self contained microprocessor for diesel generator sets. The SG+ 1.5 display is mounted on the control box cover. The SG+ 1.5 microprocessor is mounted inside the control box. Three external relays - two ECU Relays and the Start Relay are also mounted inside the control box near the microprocessor.

  • Page 27: Microprocessor

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Microprocessor RAJ808 J6 Connector –...

  • Page 28: Controller Overview

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Controller Overview RAJ1118 A vacuum lucent display on the front panel shows operating information including output voltage, current...

  • Page 29: Miscellaneous Controller Features

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Miscellaneous Controller Features •...

  • Page 30: S S G G + + 1 1 . . 5 5 C C O O N N T T R R O O L L L L E E R R A A N N D D O O P P E E R R A A T T I I N N G G I I N N S S T T R R U U C C T T I I O O N N S S

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s SG+ 1.5 - Navigating the Controller Menus Controller Display Menus The SG+ 1.5 controller contains extensive display menus that can be navigated via the keypad.
  • Page 31 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Navigating Controller Menus Moving through the menus and their submenus and entering commands requires the use of the following keys: RAJ607...

  • Page 32: Menu Overview

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Menu Overview Press the U U P P o o r r D D O O W W N N keys to scroll through the Main Menu or a Submenu.

  • Page 33: Data Menu

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Data Menu The Data Menu contains the following submenus.

  • Page 34: Event Log Menu

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Event Log Menu The Event Log Menu contains the following submenus: •...

  • Page 35: Pause Mode Displays

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Pause Mode Displays W W A A R R N N I I N N G G R R i i s s k k o o f f I I n n j j u u r r y y ! !

  • Page 36: Controller Link Down Display

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Controller Link Down Display The Controller Link Down display indicates there is no communication between the SG+ 1.5 controller and the display.

  • Page 37: Sg+ 1.5 New Controller Set Up

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s SG+ 1.5 New Controller Set Up When a new SG+ 1.5 controller is installed and used for the first time, it must be set up for the unit to work properly.
  • Page 38 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s NOT DEF ENGINE GENERATOR...
  • Page 39 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s 9.
  • Page 40 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s 11.

  • Page 41: Sg+ 1.5 Operating Instructions

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s SG+ 1.5 Operating Instructions Pretrip Inspection The pretrip inspection is an important part of the preventive maintenance program.

  • Page 42: After Start Inspection

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s •...

  • Page 43: Main Menu

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Main Menu The Main Menu contains the following menus: •...

  • Page 44: Engine Menu

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Engine Menu The Engine display the following unit operating information: •...
  • Page 45 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s To "ENGINE"...

  • Page 46: Generator

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Generator The Generator submenu display the status of the following outputs: •...

  • Page 47: Unit

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Unit The Unit submenu display the status of the following outputs: •...

  • Page 48: Internal States

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Internal States The Internal States displays which of the following states the unit is in as it prepares to start, and after it starts or if it shuts down:...

  • Page 49: Alarm List Menu Sg+ 1.5

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Alarm List Menu SG+ 1.5 The Alarm List Menu displays alarms.

  • Page 50: Alarm Diagnosis

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s To "ALARM LIST"...
  • Page 51 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Alarm Type–Cause Diagnostics Alarm Code...
  • Page 52 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Alarm Type–Cause Diagnostics Alarm Code...
  • Page 53 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Alarm Type–Cause Diagnostics Alarm Code...

  • Page 54: Message List Menu Sg+ 1.5

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Message List Menu SG+ 1.5 The Message List Menu displays messages.
  • Page 55 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s To "MESSAGE LIST"...

  • Page 56: Commands Menu

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Commands Menu The Commands Menu contains the following submenus that are used to test the operation or the unit and controller: •...

  • Page 57: Pretrip Inspection Test (Pti)

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Pretrip Inspection Test (PTI) To properly perform a PTI (Pretrip Inspection Test) on units equipped with a SG+ controller, do not apply a load to the alternator.

  • Page 58: Manual Function Test

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Manual Function Test The Manual Function Test submenu contains the following component tests: •...

  • Page 59: Speed Control

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Speed Control Speed control is used to temporarily set engine speed (either high or low speed) to aid in unit testing for 180 seconds.
  • Page 60 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s To "MISC.

  • Page 61: C/F Temperature And Language Mode

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s C/F Temperature and Language Mode The C/F Mode submenu is used the change: - - L L a a n n g g u u a a g g e e : : Allows unit to display English, Spanish, or Danish for all screens.
  • Page 62 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s MAIN MENU MISC.

  • Page 63: Sw/Hw Version (Software / Hardware)

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s SW/HW Version (Software / Hardware) The SW/HW Application Version submenu displays the following information about the controller: •...

  • Page 64: Timers

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Timers The Timers submenu displays the following hour meters: •...
  • Page 65 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s MAIN MENU MISC.

  • Page 66: Counters

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Counters The Counters submenu displays the following event counters: •...

  • Page 67: Date And Time

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Date and Time The Date and Time submenu is used to set the date clock in the controller.
  • Page 68 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s MAIN MENU MISC.

  • Page 69: Configuration Menu

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Configuration Menu The Configuration Menu is used to configure the following controller functions (also see the flowcharts on the following pages):...
  • Page 70 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s MAIN MENU CONFIGURATION CONFIGURATION...

  • Page 71: Controls

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Controls The Controls submenu is used to temporary set engine RPM to AUTO / HIGH / LOW for service purposes.
  • Page 72 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s MAIN MENU CONFIGURATION CONFIGURATION...

  • Page 73: Unit Configuration

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Unit Configuration The unit configuration submenu contain the following settings and is used to set up the controller for the specific unit it is controlling:...
  • Page 74 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s •...
  • Page 75 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s •...

  • Page 76: Option Configuration

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s 8.
  • Page 77 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s MAIN MENU CONFIGURATION CONFIGURATION...

  • Page 78: System Configuration

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s System Configuration The System Configuration submenu allows the use to set the unit ID number.
  • Page 79 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s 8.

  • Page 80: Misch Configuration

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s MISCH Configuration The MISCH Configuration is used as a factory reset for all settings.

  • Page 81: Event Log Menu

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Event Log Menu The Event Log Menu allows user access to view saved events and to perform a USB download.

  • Page 82: Events

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Events The Event Log is a list of events that are recorded in the controller memory.

  • Page 83: Fuel Events

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Fuel Events The Fuel Events is a list of fuel events that are recorded in the controller memory on units equipped with the fuel level sensor option.

  • Page 84: Usb Copy Event Log

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s USB Copy Event Log The USB Copy Event Log is a function that allows the download of all logged events onto a USB drive located on the controller board.
  • Page 85 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s MAIN MENU EVENT LOG EVENT LOG...

  • Page 86: Logview And Viewing Sg+ Logs

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s LogView and Viewing SG+ Logs With the release of LogView software version 5.9.2.0 (or later), you can now view SG+ Event logs.
  • Page 87 S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Figure 3.

  • Page 88: Setting Hour Meter Thresholds And Resetting Hour Meters

    S S G G + + 1 1 . . 5 5 C C o o n n t t r r o o l l l l e e r r a a n n d d O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Setting Hour Meter Thresholds and Resetting Hour Meters The Hour Meter Threshold feature sets the controller to alert the user that the unit has operated for a defined number of hours.

  • Page 89: Battery

    Electrical Maintenance Battery C C A A U U T T I I O O N N R R i i s s k k o o f f I I n n j j u u r r y y ! ! P P l l a a c c e e t t h h e e u u n n i i t t O O n n / / O O f f f f s s w w i i t t c c h h i i n n t t h h e e “...

  • Page 90: Relays

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Relays All the relays are 12 Vdc relays.

  • Page 91: Fuses

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 4.
  • Page 92 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e The alternator exciter field is controlled by the DSR.

  • Page 93: Emi 3000

    Engine Maintenance EMI 3000 EMI 3000 is an extended maintenance interval package. The EMI 3000 package consists of the following key components: • EMI 3000-Hour Cyclonic Air Cleaner Assembly and Air Cleaner Element • EMI 3000-Hour 5-Micron Fuel Filter • EMI 3000-Hour Dual Element Oil Filter (blue with white lettering) •...

  • Page 94: Low Oil Pressure

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Low Oil Pressure Oil pressure is affected by oil temperature, oil viscosity, and engine speed. •...

  • Page 95: Extended Life Coolant (Elc)

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e head and returns it to the radiator. A thermostat mounted in the coolant outlet line from the cylinder head to the radiator automatically maintains coolant temperature within the specified temperature range.

  • Page 96: Antifreeze Maintenance Procedure

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Antifreeze Maintenance Procedure As with all equipment containing antifreeze, periodic inspection on a regular basis is required to verify the condition of the antifreeze.

  • Page 97: Engine Thermostat

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Remove the plug from the front end of the water pump below the thermostat housing as shown (Figure 7, p.

  • Page 98: Engine Fuel System

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Engine Fuel System The components of the fuel system are: •...
  • Page 99 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e • Fuel transfer pump replacement or repair. •...
  • Page 100 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Bleed Screw Fuel Filter/Water Separator Mono-plunger and Distributor Injection Pump 61979-4-MM-EN...

  • Page 101: Fuel Return Line Replacement

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Fuel Return Line Replacement Use the following procedure to replace the fuel return lines and end cap. 1.

  • Page 102: Draining Water From Fuel Tank

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e 6. Tighten the injection lines. 7. Start the engine and observe the engine run for a few minutes. If the engine fails to start, or starts but stops in a few minutes, repeat the procedure.
  • Page 103 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Make the engine speed adjustments with the engine fully warmed up. 61979-4-MM-EN...

  • Page 104: Injection Pump Timing

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Injection Pump Timing Use this timing procedure when installing a new injection pump. It is not necessary to use this timing procedure when removing and reinstalling the original injection pump.
  • Page 105 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Index Mark on Injection Pump Existing Index Mark on Gear Case Make New Mark on Gear Case If Needed 2.
  • Page 106 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 16. Removing Injection Pump Gear Do Not Loosen or Remove These Four Bolts Remove Nut and Lock Washer 4.
  • Page 107 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 18. Injection Angle Mark Injection Angle Mark N N o o t t e e : : If you cannot read the injection angle mark, contact the Thermo King Service Department with the injection pump serial number or the engine serial number and they will provide the injection angle.
  • Page 108 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 20. Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker Injection Pump Index Mark at –0.6 Degrees Injection Pump Index Mark at +1.8 Degrees 8.

  • Page 109: Injection Pump Removal

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 22. Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover Crankshaft Gear Oil Pump Cover Outer Rotor...
  • Page 110 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 24. Index Mark Alignment Index Mark on Injection Pump Index Mark on Gear Case 2.

  • Page 111: Injection Pump Reinstallation

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 25. Injection Pump Gear Tool Injection Pump Adapter (Tool) Gear Case...

  • Page 112: Engine Valve Clearance Adjustment

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e N N o o t t e e : : The fuel solenoid must be energized when it is installed. If not, the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly.
  • Page 113 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Index Mark Top Dead Center Mark for 1 and 4 b.

  • Page 114: Crankcase Breather

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Valve Adjustments and Cylinder Configurations Rear Flywheel Front Pulley End Cylinder Number Valve arrangement...

  • Page 115: Emi 3000 Air Cleaner

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Crankcase Typical Cause Pressure Effect Increase Piston Rings Stuck or Worn Increase Breather Hose or Restrictor Plugged...
  • Page 116 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e 2. Access the front of the engine. 3.
  • Page 117 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e 4. Move the fan forward into the shroud. DO NOT allow the fan to contact the radiator fins. 5.
  • Page 118 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Belt Installation and Tension Setting 1. Install the belt around the crankshaft pulley and water pump inner sheave hub. 2.

  • Page 119: General Description

    Alternator Operation and Diagnosis General Description The 460/230 Vac alternator consists of three principal components: the main alternator, the integral direct-connected exciter, and an externally mounted excitation control system. The main alternator may be subdivided into the 4-pole rotating main field and the alternator stator (ALT). The rotating main field, the rotating rectifier and the exciter armature are all mounted on a common shaft.

  • Page 120: Alternator Function

    A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s Alternator Function Starting Excitation The initial excitation for the alternator is supplied by residual magnetism in the main field.

  • Page 121: Test Instruments

    A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s 1.

  • Page 122: Test 2 - Alternator Exciter Field Testing

    A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s 4.
  • Page 123 A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s Figure 33.

  • Page 124: Test 4- Exciter And Diode Test

    A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s Test 4- Exciter and Diode Test Test 4 covers testing the exciter and diodes.
  • Page 125 A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s Figure 34.

  • Page 126: Megohmmeter

    A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s RAJ872 Megohmmeter The use of a megohmmeter can be a valuable addition to the repair and maintenance of the generator set.

  • Page 127: Field Coils, Stator Windings

    A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s Field Coils, Stator Windings Visually inspect the field coils and stator windings, their leads and connections to determine if they are electrically and mechanically satisfactory.

  • Page 128: Alternator Replacement

    A A l l t t e e r r n n a a t t o o r r O O p p e e r r a a t t i i o o n n a a n n d d D D i i a a g g n n o o s s i i s s Figure 35.

  • Page 129: Unit Inspection

    Structural/Accessory Maintenance Unit Inspection Inspect the unit during unit pre-trip inspection and scheduled maintenance intervals. Look for loose or broken wires or hardware, and other physical damage which might affect unit performance. Repair if required. N N o o t t e e : : See Maintenance Inspection Schedule chapter in this manual for the correct service interval for your unit. 250 or 500 hour inspection/service intervals are required in extreme operating conditions.

  • Page 130: Sgsm Typical Unit Installation

    S S t t r r u u c c t t u u r r a a l l / / A A c c c c e e s s s s o o r r y y M M a a i i n n t t e e n n a a n n c c e e SGSM Typical Unit Installation 1.

  • Page 131: Sgsm Keener Arm Unit Installation

    S S t t r r u u c c t t u u r r a a l l / / A A c c c c e e s s s s o o r r y y M M a a i i n n t t e e n n a a n n c c e e SGSM Keener Arm Unit Installation 1.

  • Page 132: Sgcm Unit Installation

    S S t t r r u u c c t t u u r r a a l l / / A A c c c c e e s s s s o o r r y y M M a a i i n n t t e e n n a a n n c c e e SGCM Unit Installation 1.

  • Page 133: Sgco Clip-On Corner Clamp Unit Installation

    S S t t r r u u c c t t u u r r a a l l / / A A c c c c e e s s s s o o r r y y M M a a i i n n t t e e n n a a n n c c e e SGCO Clip-on Corner Clamp Unit Installation 1.
  • Page 134 S S t t r r u u c c t t u u r r a a l l / / A A c c c c e e s s s s o o r r y y M M a a i i n n t t e e n n a a n n c c e e Figure 36.

  • Page 135: Telematics General Description

    Telematics Information Telematics General Description The telematics system allows the unit owner real-time remote genset monitoring and management access. This system monitors and communicates the following information to the unit owner through the Thermo King Telematics System: • Asset Name •...

  • Page 136: Telematics Component Locations

    T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n Telematics Component Locations Figure 37.
  • Page 137 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n RAJ1052 I I m m p p o o r r t t a a n n t t : : The ability of the device to call in depends on the availability and strength of the GSM / CELL signal.
  • Page 138 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n G G P P S S C C O O M M M M U U N N I I C C A A T T I I O O N N C C Y Y C C L L E E : : Location records are obtained every 10 minutes which can be identified by: •...

  • Page 139: Telematics Diagnostic Information

    T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n Telematics Diagnostic Information I I m m p p o o r r t t a a n n t t : : The telematics system (when operating normally) will communicate with the unit owner non-stop - even when the SG unit is turned OFF.
  • Page 140 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n RAJ1059 5.
  • Page 141 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 7.

  • Page 142: Telematics Fuel Level Sensor (Optional)

    T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n N N o o t t e e : : The SG controller will show a communication error on the screen of the microprocessor is not communicating.
  • Page 143 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 8.

  • Page 144: Telematics Antenna

    T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 10.
  • Page 145 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n Figure 38.

  • Page 146: Pairing Telematics Module To Sg Unit

    T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n Pairing Telematics Module to SG Unit I I m m p p o o r r t t a a n n t t : : Each SG unit is uniquely paired to a telematics module on the assembly line: •...
  • Page 147 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 2.
  • Page 148 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 4.
  • Page 149 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 9.
  • Page 150 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 19.
  • Page 151 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 21.
  • Page 152 T T e e l l e e m m a a t t i i c c s s I I n n f f o o r r m m a a t t i i o o n n 25.
  • Page 153 Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Corroded battery terminals / cable Clean and tighten Battery discharged Charge or replace battery Unit Switch ON; Controller display Fuse S13 open Check circuit and replace fuse does not come on Defective ON / OFF Switch Check switch Open Circuit Check 2, 2B, 2C, and 8 circuit...

  • Page 154: M M E E C C H H A A N N I I C C A A L L D D I I A A G G N N O O S S I I S

    M M e e c c h h a a n n i i c c a a l l D D i i a a g g n n o o s s i i s s CONDITION POSSIBLE CAUSE REMEDY Air intake system clogged Clean air intake system...
  • Page 155 Diagram Index The following table lists the diagrams that are relevant to this unit. Drawing No. Drawing Title 3E79362 DIAGRAM WIRING, SG3000 SG1.5 (1 pages) 3E79363 DIAGRAM SCHEMATIC, SG3000 SG1.5 (1 pages) 61979-4-MM-EN...
  • Page 156 Figure 39. 3E79362 (1 of 1) RELEASED 04/Jun/2020 17:36:06 GMT 61979-4-MM-EN...
  • Page 157 Figure 40. 3E79363 (1 of 1) RELEASED 04/Jun/2020 17:36:06 GMT 61979-4-MM-EN...
  • Page 158 CONTROLLER MENU GUIDE 61979-4-MM-EN...
  • Page 159 STANDARD DISPLAY CONTROLLER MENU GUIDE Keypad Operating Tips Text Input: PAUSE MODE DISPLAYS deLAY / AC RESTART IN XX MIN. • To enter a number: Press the U or D key to increase or decrease the value of a digit in the display. ALARM LIST MENU •...
  • Page 160 CONTROLLER MENU GUIDE (Continued) To/From Previous Page From Previous Page • Press key to toggle between Fuel Sensor Yes and No. Fuel Sensor: No • Press key to return to System Setup Submenu. • Press key to toggle between CLD on pin 5 Yes and No.
  • Page 161 Controller Menu Guide 61979-4-MM-EN...
  • Page 162 CONTROLLER MENU GUIDE STANDARD DISPLAY Keypad Operating Tips PAUSE MODE DISPLAYS deLAY / AC RESTART IN XX MIN. Text Input: ALARM LIST MENU • To enter a number: Press the U or D key to increase or • Top line shows Alarm Code, and the position of the alarm •...
  • Page 163 CONTROLLER MENU GUIDE (Continued) To/From Previous Page • Press key to toggle between Celsius /Fahrenheit and Languages. Submenus Language • Press keys at same time to save MISC. C/F Mode new setting and return to Misc. Functions Menu. SW/HW Version MISC.
  • Page 164 Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938.

This manual is also suitable for:

Thermo king sgsm 3000eThermo king sgcm 3000eSgco 3000e718202718203718204

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